Ford Explorer: Front End Sheet Metal Repairs / Removal and Installation - Fender Apron Panel

Special Tool(s) / General Equipment

Materials

Removal

  WARNING: Electric vehicles damaged by a crash may have compromised high voltage safety systems and present a potential high voltage electrical shock hazard. Exercise caution and wear appropriate Personal Protective Equipment (PPE) safety gear, including high voltage safety gloves and boots. Remove all metallic jewelry, including watches and rings. Isolate the HV system as directed by the Ford Emergency Response Guide for the vehicle. Failure to follow these instructions may result in serious personal injury or death.

NOTICE: Battery electric vehicle (BEV), hybrid electric vehicle (HEV) and plug-in hybrid electric vehicle (PHEV) contain a high-voltage battery. Before cutting or welding near the high-voltage battery it must be removed to avoid damage.

NOTE: Left hand (LH) side shown, right hand (RH) side similar.

1.   WARNING: Before beginning any service procedure in this manual, refer to health and safety warnings in section 100-00 General Information. Failure to follow this instruction may result in serious personal injury.

   Refer to: Health and Safety Precautions (100-00 General Information, Description and Operation).
   Refer to: High Voltage System Health and Safety Precautions - Overview (100-00 General Information, Description and Operation).
   

1. Remove the fender and splash shield.
   Refer to: Fender (501-02 Front End Body Panels, Removal and Installation).
   Refer to: Fender Splash Shield (501-02 Front End Body Panels, Removal and Installation).
   

1. Remove the grille opening panel.
   Refer to: Radiator Grille Opening Panel (501-02 Front End Body Panels, Removal and Installation).
   

1. Remove the front bumper.
   Refer to: Front Bumper (501-19 Bumpers, Removal and Installation).
   

1. Remove the cooling module.
   Refer to: Cooling Module (303-03A Engine Cooling - 2.3L EcoBoost (201kW/273PS), Removal and Installation).
   Refer to: Cooling Module (303-03B Engine Cooling - 3.0L EcoBoost, Removal and Installation).
   Refer to: Cooling Module (303-03C Engine Cooling - 3.3L Duratec-V6, Removal and Installation).
   Refer to: Cooling Module (303-03D Engine Cooling - 3.3L Duratec-V6 – Hybrid (BP), Removal and Installation).
   

1. Remove the cowl grille and panel.
   Refer to: Cowl Panel Grille (501-02 Front End Body Panels, Removal and Installation).
   Refer to: Cowl Panel (501-02 Front End Body Panels, Removal and Installation).
   

1. Remove the upper radiator support.
   

1. If Required:
   Dimensionally restore the vehicle to pre-damage condition.
   Refer to: Body and Frame (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation).
   

1. Remove the welds and fender bracket.
   Use the General Equipment: Spot Weld Drill Bit

1. Remove the welds.
   Use the General Equipment: Spot Weld Drill Bit

1. Remove the welds and rivets.
   Use the General Equipment: Spot Weld Drill Bit
   Use the General Equipment: Belt Sander

1. Remove the rivets.
   Use the General Equipment: Belt Sander

1. Remove the bolts.
   Use the General Equipment: Torx Bit Socket

1. NOTE: Pay particular attention to the location of adhesives and sealers to air in installation.

   Remove the fender apron panel.
   Use the General Equipment: Hot Air Gun

Installation

  WARNING: Electric vehicles damaged by a crash may have compromised high voltage safety systems and present a potential high voltage electrical shock hazard. Exercise caution and wear appropriate Personal Protective Equipment (PPE) safety gear, including high voltage safety gloves and boots. Remove all metallic jewelry, including watches and rings. Isolate the HV system as directed by the Ford Emergency Response Guide for the vehicle. Failure to follow these instructions may result in serious personal injury or death.

NOTICE: Battery electric vehicle (BEV), hybrid electric vehicle (HEV) and plug-in hybrid electric vehicle (PHEV) contain a high-voltage battery. Before cutting or welding near the high-voltage battery it must be removed to avoid damage.

NOTICE: The high-voltage battery in a battery electric vehicle (BEV), hybrid electric vehicle (HEV) or plug-in hybrid electric vehicle (PHEV) can be affected and damaged by excessively high temperatures. The temperature in some body shop paint booths can exceed 60° C (140° F). Therefore, during refinishing operations, the paint booth temperature must set at or below 60° C (140° F) with a bake time of 45 minutes or less. Temperatures in excess of 60° C (140° F) or bake durations longer than 45 minutes will require the high-voltage battery be removed from the vehicle prior to placing in the paint booth.

NOTICE: If refinishing cure temperatures exceed 60° C (140° F), the charge port light ring on plug-in vehicles must be removed.

NOTE: Factory welds may be substituted with resistance or metal inert gas (MIG) plug welds. Resistance welds may not be placed directly over original location. They must be placed adjacent to original location and match factory welds in quantity. Metal inert gas (MIG) plug welds must equal factory welds in both location and quantity.

NOTE: Left hand (LH) side shown, right hand (RH) side similar.

1. Drill for rivet installation.
   Use the General Equipment: 6.5 mm Drill Bit

1. Apply adhesive.
   Material: Metal Bonding Adhesive / TA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B

1. Install, properly position and clamp the fender apron panel.
   Use the General Equipment: Locking Pliers

1. Install the bolts.
   Use the General Equipment: Torx Bit Socket
   Torque: 35 lb.ft (47 Nm)

1. Drill for rivets.
   Use the General Equipment: 6.5 mm Drill Bit

1. Install the rivets.
   

   Item	SPR Number	SPR Code	Henrob® Mandrel	Pro-Spot® Mandrel	Blind Rivet	Solid Rivet	Rivnut®
   1	-	-	-	-	W702512-S900C	-	-

   Use the General Equipment: Rivet Gun

1. Install the rivets.
   

   Item	SPR Number	SPR Code	Henrob® Mandrel	Pro-Spot® Mandrel	Blind Rivet	Solid Rivet	Rivnut®
   1	-	-	-	-	W702512-S900C	-	-

   Use the General Equipment: Rivet Gun

1. Install the welds.
   Use the General Equipment: Resistance Spotwelding Equipment

1. Install the welds.
   Use the General Equipment: MIG/MAG Welding Equipment

1. Drill plug weld holes in the fender bracket.
   Use the General Equipment: 8 mm Drill Bit

1. Install the fender bracket and welds.
   Use the General Equipment: Resistance Spotwelding Equipment
   Use the General Equipment: MIG/MAG Welding Equipment

1. Seam Sealing:
   All seams must be sealed to production level.
   Material: Seam Sealer / TA-2-B, 3M™ 08308, LORD Fusor® 805DTM

1. Metal finish all welds as necessary using typical metal finishing techniques and materials.
   

1. Refinish the entire repair using a Ford approved paint system.
   

1. Restore corrosion protection.
   Refer to: Corrosion Prevention (501-25 Body Repairs - General Information, General Procedures).
   

1. Install the cowl panel and grille.
   Refer to: Cowl Panel (501-02 Front End Body Panels, Removal and Installation).
   Refer to: Cowl Panel Grille (501-02 Front End Body Panels, Removal and Installation).
   

1. Install the cooling module.
   Refer to: Cooling Module (303-03A Engine Cooling - 2.3L EcoBoost (201kW/273PS), Removal and Installation).
   Refer to: Cooling Module (303-03B Engine Cooling - 3.0L EcoBoost, Removal and Installation).
   Refer to: Cooling Module (303-03C Engine Cooling - 3.3L Duratec-V6, Removal and Installation).
   Refer to: Cooling Module (303-03D Engine Cooling - 3.3L Duratec-V6 – Hybrid (BP), Removal and Installation).
   

1. Install the front bumper.
   Refer to: Front Bumper (501-19 Bumpers, Removal and Installation).
   

1. Install the grille opening panel.
   Refer to: Radiator Grille Opening Panel (501-02 Front End Body Panels, Removal and Installation).
   

1. Install the upper radiator support and bolts.
   Torque: 22 lb.ft (30 Nm)

1. Install the fender and splash shield.
   Refer to: Fender (501-02 Front End Body Panels, Removal and Installation).
   Refer to: Fender Splash Shield (501-02 Front End Body Panels, Removal and Installation).